Apparatus and method for attaching filamentary members to a substrate

ABSTRACT

An apparatus and a method for attaching filamentary members to a substrate are disclosed. The substrate includes a plastic layer and the apparatus includes an anvil, a needle and a swaging tool movable relatively to the anvil. The method includes the steps of penetrating the substrate with the needle to create an opening, positioning the filamentary member in the opening, and compressing the substrate between the swaging tool and the anvil so as to deform the plastic layer and swage the filamentary member to the substrate. The needle is heated to melt the plastic layer so that it fuses with the filamentary member upon swaging. Motion of the needle and swaging tool is controlled by cams under the command of a microprocessor control unit. A substrate to which filamentary members are swaged is also disclosed.

FIELD OF THE INVENTION

This invention concerns a device and a method for attaching filamentarymembers, particularly optical fibers, to a substrate.

BACKGROUND OF THE INVENTION

Various methods and devices are available for attaching optical fibersto a substrate in a particular pattern which becomes visible when theoptical fiber ends are illuminated. Such patterns may form merelydecorative devices as well as trademarks associated with advertising aparticular product or service or other words, phrases or symbolsassociated with or promoting an organization, event or thing. Thesubstrate to which the optical fibers are attached could be a banner ora part of an article of clothing such as a hat or a coat. The opticalfibers and their associated illuminating means (typically batterypowered light emitting diodes) are hidden within a lining or on theinside of the garment or on a reverse side of the banner with only theilluminatable ends visible on an outwardly facing surface of thesubstrate.

Disadvantages associated with current devices and methods for attachingoptical fibers to substrates include the slowness of the procedures andtheir use of an adhesive to fix the optical fiber to the substrate.Devices currently available require on the order of six seconds perattachment and use liquid adhesives cured by exposure to ultravioletlight. The use of liquid adhesive complicates the attachment device andmethod and increases the cost of production due to the use of arelatively expensive consumable (the adhesive) which must be constantlyreplenished. The relatively long duration of time required to attacheach fiber makes complicated designs requiring many fibers impracticalfor economic mass production. There is clearly a need for improvedmachines and methods of attachment of filamentary members, such asoptical fibers, to a substrate.

SUMMARY AND OBJECTS OF THE INVENTION

The invention concerns an apparatus for attaching a filamentary memberto a substrate having a plastic layer. In a preferred embodiment, theapparatus comprises a support surface positionable facing the substrateand engageable with it. A needle is movable relatively to the substrateand adapted to penetrate it and form an opening therethrough. Theopening is positionable adjacent to the support surface. Preferably, thesupport surface is fixed and the needle is movable through an aperturelocated in the support surface.

A swaging tool having a swaging surface is positioned with the swagingsurface facing the support surface. The swaging tool and the supportsurface are movable relatively to one another so as to compress thesubstrate between the swaging surface and the support surface.Preferably, the swaging tool moves relative to the support surface. Theswaging tool has a passageway therein for receiving the filamentarymember. The passageway is alignable with the opening in the substrateformed by the needle. The filamentary member is positionable through thepassageway and into the opening. When the substrate is compressedbetween the support surface and the swaging tool, the swaging surfacedeforms a portion of the plastic layer around the opening so as to swagethe filamentary member to the substrate.

Preferably, a heater is mounted on the needle, the needle being heatedand melting the portion of the plastic layer upon forming the opening inthe substrate.

It is convenient to include an outer sleeve positioned within theaperture through the support surface. The outer sleeve has a lengthwiseoriented bore for receiving the needle therein. The outer sleeve ismovable relatively to the needle to extend outwardly from the supportsurface and penetrate the substrate layer along with the needle. Thebore of the outer sleeve forms a guide for directing the filamentarymember into the opening in the substrate when the needle and the outersleeve have penetrated the substrate and the needle is moved away fromthe substrate relatively to the outer sleeve.

It is also preferable to use a stripper tube having a lengthwise boretherethrough. The swaging tool is positioned within the stripper tubebore and is movable relatively thereto. The stripper tube is movablerelatively to the support surface and has an end engageable with thesubstrate for separating the substrate from the swaging tool when theswaging tool is moved away from the substrate relatively to the strippertube.

Motion of the stripper tube, swaging tool, needle and outer sleeve ispreferably coordinated by cams. In practice, the apparatus includes afirst cam rotatable about a first axis and a first cam follower engagingthe first cam and mounted on the stripper tube. The first cam moves thestripper tube toward and away from the support surface as it rotates.The apparatus also includes a second cam rotatable about a second axisand a second cam follower engaging the second cam and mounted on theswaging tool. The second cam moves the swaging tool toward and away fromthe support surface. A third cam, rotatable about a third axis,cooperates with a third cam follower mounted on the needle. The thirdcam moves the needle through the aperture in the support surface toextend from or retract the needle beneath the support surface. The camsare shaped and rotated so as to coordinate the relative motion of thestripper tube, the needle and the swaging tool for swaging thefilamentary member to the substrate.

The apparatus may also comprise a fourth cam rotatable about a fourthaxis and cooperating with a fourth cam follower mounted on the outersleeve surrounding the needle. The fourth cam moves the outer sleevethrough the aperture to extend from or retract beneath the supportsurface in cooperation with the needle, the stripper tube and theswaging tool. Note that the various cam axes may be distinct from oneanother or coincident, as they merely serve to illustrate the axis ofrotation of the various cams.

The apparatus also preferably includes a pair of nip rollers mounted forrotation in opposite directions and having respective circumferentialsurfaces engaging the filamentary member on opposite sides thereof. Therollers are positioned above the swaging tool and, upon rotation, feedthe filamentary member through the passageway of the swaging tool andinto the opening in the substrate.

It is convenient to use a frame for supporting the substrate. The frameis positioned between the support surface and the stripper tube and ismovable transversely thereto for positioning a predetermined location onthe substrate beneath the swaging tool for attachment of the filamentarymember at the predetermined location.

The invention also contemplates a method of attaching a filamentarymember to a substrate having a plastic layer. The method comprises thesteps of:

(A) forming an opening through the substrate at a predetermined locationon the substrate;

(B) inserting the filamentary member through the opening; and

(C) deforming a portion of the plastic layer surrounding the openinginto contact with the filamentary member.

In the method according to the invention, the deforming step includesswaging the portion of the plastic layer. The swaged portion ispreferably formed into a conical shape surrounding the filamentarymember. The deforming step may also include melting the portion of theplastic layer prior to or during swaging or otherwise deforming thelayer. The deforming step may also include fusing the portion of theplastic layer to or with the filamentary member.

The invention also includes a substrate having a filamentary memberattached according to the invention. The substrate comprises a plasticlayer and a filamentary member extending transversely through thesubstrate and attached thereto by deforming a portion of the plasticlayer surrounding the filamentary member into contact with thefilamentary member.

It is an object of the invention to provide an apparatus that can attachfilamentary members to a substrate rapidly and precisely.

It is another object of the invention to provide an apparatus that isrelatively simple to program and operate.

It is yet another object of the invention to provide a method forattaching a filamentary member to a substrate that does not use anadhesive.

It is still another object of the invention to provide a method forattaching a filamentary member to a substrate which is inexpensive.

It is again another object of the invention to provide a method forattaching a filamentary member to a substrate that provides a relativelyhigh pull-out load between the filamentary member and the substrate.

It is also another object of the invention to provide an article whereinfilamentary members are attached to a substrate.

These and other objects and advantages of the invention will becomeapparent upon consideration of the drawings and following detaileddescription.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an apparatus for attaching filamentarymembers to a substrate according to the invention;

FIG. 2 is an elevational view of the apparatus shown in FIG. 1;

FIG. 2A is a partial sectional view taken at line 2A—2A of FIG. 1;

FIG. 3 is a front view of the apparatus shown in FIG. 1;

FIG. 4 is a partial sectional view taken at line 4—4 of FIG. 2;

FIG. 5 is a view on an enlarged scale of a portion of the apparatusshown in FIG. 3;

FIG. 5A is a detailed view on an enlarged scale of a portion of FIG. 5within the broken circle;

FIGS. 6A and 6B are partial sectional views taken at line 6—6 in FIG. 3;

FIG. 7 is a view on an enlarged scale of a portion of the apparatusshown within the broken circle 7 in FIG. 6A;

FIG. 8 is a view on an enlarged scale of a portion of the apparatusshown within the broken circle 8 in FIG. 6B; and

FIGS. 9-14 show a series of views depicting the operation of theapparatus shown in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 shows an apparatus 10 for attaching filamentary members to asubstrate according to the invention. Apparatus 10 has a base 12 onwhich is mounted a stanchion 14. An x-y table 16 is mounted on stanchion14, the table having an x-direction actuator 18 and a y-directionactuator 20 for moving the table transversely in the x and y directionsas defined by arrows 22 and 24. Table 16 may take any practical formnecessary to hold a substrate 26 (shown in broken line) to whichfilamentary members are to be attached, the table being shown by way ofexample as a tentering frame 28 mounted on the actuators 18 and 20 fortensioning and positioning the substrate 26 for presentation to thefilamentary member insertion assembly described below.

An upper mounting plate 30 is attached to stanchion 14 and positionedabove x-y table 16 via a horizontally extending beam 32, shown in brokenline. An upper cam wheel 34 is mounted on the upper mounting plate. Asbest shown in FIG. 2, the upper cam wheel 34 is mounted in a bearing 36for rotation about an axis 38. An upper drive shaft 40 is connected tothe upper cam wheel 34 and extends through beam 32 from bearing 36 toanother bearing 42 mounted within the stanchion 14. An electric motor44, also preferably mounted on the stanchion 14 powers the upper driveshaft 40 via a drive belt assembly 46 positioned within stanchion 14 andshown in hidden line. Other means of powering the drive shaft, such as ageared transmission or direct motor drive are also feasible.

As best shown in FIG. 3, upper cam wheel 34 comprises two upper cams 48and 50, defined by cam surfaces which appear respectively asnon-circular grooves 48 a and 50 a in the upper cam wheel 34. Cams 48and 50 rotate about respective axes of rotation 38 a and 38 b, bestshown in FIG. 2. The axes coincide with one another and with the axis 38of the upper cam wheel 34 since both cams 48 and 50 are mounted on thecam wheel 34. However, the cams could also be independently mounted, inwhich case, the axes of rotation might not be coincident. As describedbelow, cam followers of various reciprocating components of thefilamentary member insertion assembly ride in the grooves 48 a and 50 a,the shape of the grooves and their angular relation to one anothercoordinating the relative movements of the reciprocating components ofthe filamentary member insertion assembly.

FIG. 3 also shows the filamentary member feed assembly 52 which ismounted on the upper mounting plate 30. Feed assembly 52 comprises anelectric motor 54 (see also FIG. 4) which turns two nip rollers 56 and58 about respective axes of rotation 60 and 62 which are substantiallyparallel to each other and perpendicular to the upper mounting plate 30.A belt drive 64 extends from the motor and is configured tosimultaneously rotate both nip rollers in opposite directions. Afilament guide block 66 is positioned between the nip rollers 56 and 58.As shown on an enlarged scale in FIG. 5, the filament guide block 66 iscontoured to complement the shape of the nip rollers 56 and 58 and allowthem to be positioned closely adjacent to each other at a point alongtheir circumferences shown within the broken line circle marked FIG. 5A.Guide block 66 has a channel 68 extending therethrough which receives afilamentary member 70, such as an optical fiber, for insertion into thesubstrate. Preferably, the filamentary member 70 is drawn from a spool(not shown) and is received within the channel 68 where it is guidedbetween the nip rollers 56 and 58. FIG. 5A shows in detail the action ofthe nip rollers engaging the filamentary member 70 for feeding it to theinsertion assembly. Guide block 66 has a gap 72 which exposes thefilamentary member 70 to the mutually facing circumferential surfaces 74and 76 of the nip rollers 56 and 58. Preferably these surfaces areformed from a compliant material layer 78 such as rubber and are incontact or spaced apart from each other so as to forcibly contact thefilamentary member 70, draw it from its spool and force it through thechannel 68 in guide block 66 when the nip rollers 56 and 58 are turnedby the feed assembly motor 54. The compliant material layer 78 is usedto prevent damage to the filamentary member 70 while insuring adequatepurchase between it and the nip rollers to provide feeding of accuratelengths of the filamentary member precisely timed to coordinate with thecomponents of the insertion assembly described below.

FIG. 1 shows a lower mounting plate 80 positioned beneath x-y table 16.A lower cam wheel 84 is mounted on the lower mounting plate. As bestshown in FIG. 2, the lower cam wheel 84 is mounted in a bearing 86attached to the lower mounting plate 80, the bearing 86 permittingrotation of the lower cam wheel 84 about an axis 88. Mounting plate 80is slidably mounted on a block 81 attached to the base 12 and tostanchion 14 by a beam 82. Movement of the lower mounting plate 80relative to block 81 is effected by an actuator, preferably a pneumaticcylinder 83 mounted on the lower mounting plate 80 and engaging theblock 81. As shown in FIG. 2, extension of the pneumatic cylinder 83positions the lower mounting plate in the operating position, and, asshown in FIG. 2A, retraction of the pneumatic cylinder 83 allows thelower mounting plate 80 and all components mounted thereon to movedownwardly. To maintain a true orientation of the lower mounting plate80 during and after adjustment, an elongated vertically oriented track85 is mounted on the block 81. Track 85 is engaged by wheels 87 mountedon the lower mounting plate 80, engagement of the wheels and trackguiding the motion of the lower mounting plate 80 relatively to theblock 81.

A lower drive shaft 90 is connected to the lower cam wheel 84 andextends from bearing 86 to another bearing 92 mounted within thestanchion 14. A drive belt assembly 96 (shown in hidden line) ispositioned within stanchion 14 and connects the lower drive shaft 90 tothe upper drive shaft 40 so that both drive shafts and their respectivelower and upper cam wheels 84 and 34 may be turned by motor 44. Flexiblecouplings 104 couple the lower drive shaft between the bearings 86 and92 and allow the shaft to be readily adjusted through an angle 106 toaccommodate the relative motion of the lower mounting plate 80 to theblock 81 as illustrated by a comparison of FIGS. 2 and 2A. Adjusting thevertical position of lower mounting plate 80 by means of the pneumaticactuator 83 permits precise, adjustable positioning of the filamentarymember insertion assembly (described below) as well as the ability tomore easily position a substrate between the components of the insertionassembly by separating its components. A shock absorber 102 isadjustably mounted on the lower mounting plate 80 and engages the block81. The shock absorber 102 is adjustable, for example by means of ascrew thread and jam nut, and damps the relative motion between thelower mounting plate 80 and the block 81 when the lower mounting plateis moved by the pneumatic actuator 83.

As best shown in FIG. 3, lower cam wheel 84 comprises two lower cams 98and 100, defined by cam surfaces which appear respectively asnon-circular grooves 98 a and 100 a in the lower cam wheel 84. Cams 98and 100 rotate about respective axes of rotation 88 a and 88 b, bestshown in FIG. 2. The axes coincide with one another and with the axis 88of the lower cam wheel 84 since both cams 98 and 100 are mounted on thecam wheel 84. However, the cams could also be independently mounted, inwhich case the axes of rotation might not be coincident. As describedbelow, cam followers of various reciprocating components of thefilamentary member insertion assembly ride in the grooves 98 a and 100a, the shape of the grooves and their angular relation to one another aswell as their relation to grooves 48 a and 50 a on the upper cam wheel40 coordinating the relative movements of the reciprocating componentsof the filamentary member insertion assembly.

The filamentary member insertion assembly 108 is shown in FIGS. 1 and 3and comprises an upper unit 110 and a lower unit 112. It should be notedthat the relative placement of the various components, as well as theirdescription as “upper” or “lower”, is arbitrary and made for the sake ofconvenience and illustration only, it being understood that a practicalapparatus may be assembled using the components in any one of manydifferent configurations and still remain within the scope of theinvention, the configuration shown and described being the preferredembodiment but by no means presenting any limitation on the invention.

Upper unit 110 comprises an upper bearing block 114 mounted on the uppermounting plate 30 between the upper cam wheel 34 and the x-y table 16.Upper bearing block 114 receives and guides two slider bars 116 and 118in reciprocal motion relatively to one another and to the x-y table 16.As best shown in FIG. 6A, slider bar 116 has a cam follower 120 at itsupper end which engages cam 50 (groove 50 a) in the upper cam wheel 34.The lower end of slider bar 116 is attached to a swaging tool 122 whichis used to fix the filamentary member to the substrate. Thus, the shapeof cam 50 will determine the timing and extent of the reciprocal motionof the swaging tool 122. The swaging tool 122 is offset from the sliderbar 116 for positioning beneath the guide block 66 of the filamentarymember feeding assembly 52 so that the filamentary member 70 may be feddownwardly through the swaging tool as described below.

Preferably, swaging tool 122 is mounted on slider bar 116 via a biasingspring 123. Spring 123 allows limited vertical motion of the swagingtool and biases it toward the substrate 26. Use of a biasing spring 123to mount the swaging tool 122 allows the swaging tool to accommodatesubstrates of different thickness without adjustment and ensures thatthe swaging tool will engage the substrate with substantially the sameforce regardless of the substrate thickness. In order to ensure constantforce engagement across a range of substrate thicknesses, it ispreferred that biasing spring 123 be an air spring comprising a piston125 movable within a cylinder 127. The pressure within the cylinder maybe adjusted to provide a particular spring rate for a substrate of aparticular thickness by injecting compressed air through nipple 129.This may be accomplished manually or automatically during machineoperation by the control unit 158.

FIG. 6A also shows slider bar 118 which has a cam follower 124 at itsupper end. Cam follower 124 engages cam 48 (groove 48 a) in the uppercam wheel 34. Note that slider bar 116 is configured to fit withinslider bar 118 so as to have the same line of action and convenientlyengage the upper cam wheel 34. The lower end of slider bar 118 isattached to a stripper tube 126 which is used to separate the swagingtool from the substrate during the insertion of the filamentary member70. Stripper tube 126 is slidable within a mounting block 131 attachedto the slider bar 118 and is spring biased toward the substrate 26 by abiasing spring 133. The stripper tube 126 is biased so that it mayaccommodate substrates of various thicknesses without adjustment butstill engage the substrate with sufficient force to perform itsfunctions which are to force the substrate down over a penetratingneedle (described below) and to separate the substrate from the swagingtool after it has performed a swaging operation, also described below.The stripper tube 126 is offset from the slider bar 118 and has alengthwise bore 128 which receives the swaging tool 122. The shape ofcam 48 will determine the timing and extent of the reciprocal motion ofthe stripper tube 124, and together, cams 48 and 50 determine therelative motion of the swaging tool 122 and the stripper tube 126 to oneanother.

FIG. 7 shows the stripper tube 126 and the swaging tool 122 in detail.As described above, swaging tool 122 moves reciprocably within the bore128 of the stripper tube 126 and has a lengthwise passageway 130 whichreceives the filamentary member 70 from the channel 68 of guide block66. Swaging tool 122 has a swaging surface 132 at one end, the swagingsurface preferably having a concave conical shape for performing aswaging operation when engaged with the substrate as described below.

As shown in FIG. 3, the lower unit 112 of the filamentary memberinsertion assembly 108 comprises a lower bearing block 134 mounted onthe lower mounting plate 80 between the lower cam wheel 84 and the x-ytable 16. Lower bearing block 134 receives and guides two slider bars136 and 138 in reciprocal motion relatively to one another and to thex-y table 16. As best shown in FIG. 6B, slider bar 136 has a camfollower 140 at its lower end which engages cam 100 (groove 100 a) inthe lower cam wheel 84. The upper end of slider bar 136 is attached to aneedle 142 which is used to penetrate the substrate during insertion ofthe filamentary member. Thus, the shape of cam 100 will determine thetiming and extent of the reciprocal motion of the needle 142. The needle142 is offset from the slider bar 136 for aligning the needle with thebore 128 of the stripper tube 126 in the upper unit 110 of thefilamentary insertion assembly 108.

FIG. 6B also shows slider bar 138 which has a cam follower 144 at itslower end. Cam follower 144 engages cam 98 (groove 98 a) in the lowercam wheel 84. Note that slider bar 136 is configured to fit withinslider bar 138 so as to have the same line of action and convenientlyengage the lower cam wheel 84. The upper end of slider bar 138 isattached to an outer sleeve 146 which is used to guide the filamentarymember into an opening in the substrate formed by needle 142 during theattachment of the filamentary member to the substrate. As shown in FIG.8, outer sleeve 146 has a lengthwise bore 148 for receiving needle 142and is offset from the slider bar 138 so as to align bore 148 withneedle 142. The shape of cam 98 will determine the timing and extent ofthe reciprocal motion of the outer sleeve 146, and together, cams 98 and100 determine the relative motion of the needle 142 and the outer sleeve146 to one another.

As shown in FIG. 6B, an anvil 150 is mounted on the lower bearing block134. Preferably, anvil 150 is fixed relatively to swaging tool 122,stripper tube 126, needle 142 and outer sleeve 146 and has a supportsurface 152 which faces the substrate. FIG. 8 shows the anvil 150, theneedle 142 and the outer sleeve 146 in detail. As described above,needle 142 moves reciprocably within the bore 148 of the outer sleeve146, and both the outer sleeve and the needle move relatively to theanvil 150. An aperture 154 through the support surface 152 is alignedwith the needle 142 and the outer sleeve 146 allowing these componentsto extend outwardly from the anvil 150 during their reciprocal motionand penetrate the substrate as described below. Preferably, both theneedle 142 and the outer sleeve 146 are heated by an electricalresistance heater 156 to which the needle 142 is mounted. As shown by acomparison of FIGS. 7 and 8, the bore 128 of stripper tube 126, thepassageway 130 of swaging tool 122, the needle 142, the bore 148 ofouter sleeve 146 and the aperture 154 through anvil 150 are allcoaxially aligned.

Preferably, the actions of the motor 44 driving the cam wheels 34 and84, the motor 54 driving the filamentary member feed assembly 52 and thex- and y-direction actuators 158 and 20 for positioning the x-y table 16are under the control of a control unit 158, shown mounted on the uppermounting plate 30 in FIGS. 1 and 4. Control unit 158 is preferablymicroprocessor based and programable so as to be able to operate theapparatus for inserting filamentary members 70 in a desired pattern in asubstrate 26 by moving the x-y table 16 via actuators 18 and 20 toposition a desired location on the substrate between the anvil 150 andthe stripper tube 126 and then activate motors 44 and 54 to drive thecams moving the upper and lower insertion units 110 and 112 of thefilamentary member insertion assembly 108 as well as the filamentarymember feed assembly 52 in a coordinated manner so as to effectattachment of the filamentary member to the substrate at the desiredlocation. The substrate 26 may be, for example, an article of clothingsuch as a hat or a jacket and the filamentary members 70 may be opticalfibers positioned with free ends extending through an outer surface ofthe clothing to display particular patterns and colors when illuminated.

Apparatus Operation

FIGS. 9 through 14 present a series of views illustrating the operationof apparatus 10. Starting with FIG. 9 (and with reference also to FIG.1), the control unit 158 has commanded the x- and y-actuators 18 and 20to move substrate 26, held in tentering frame 28, to position apredetermined location on the substrate between anvil 150 and strippertube 126. The substrate comprises a plastic layer 160, preferably formedfrom a material and having a thickness suited to the particularapplication at hand. Thermoplastics which take on a set after heatingand cooling are preferred. In particular, polyvinylchloride is favoredbecause it is inexpensive and can be obtained in a wide range ofhardnesses, from a relatively stiff formulation to provide reinforcementto the substrate, to a soft, compliant, almost gelatinous layer whichdoes not significantly affect the flexibility or “hand” of the fabricwith which it is used. Other plastics, such as polystyrene are alsofeasible. The plastics may be heated directly as by the heated needle142 or heated by pressure, as when the plastic layer is compressed asdescribed below. Pressure set plastics are also feasible. The substratemay also include one or more additional layers 162. Additional layers162 may be other plastic layers, membranous or woven, knitted or braidedtextiles as well as non-woven felts and may be formed of synthetic ornatural materials such as continuous sheet material, fibers, yarns andthe like. Although it is preferred to laminate the plastic layer 160 tothe additional layer 162, it is not necessary to do so for attaching thefilamentary member to the substrate since the process of attaching thefilamentary member to the substrate also attaches the layers 160 and 162to one another. It is also preferred to position the substrate 26 withthe plastic layer facing the swaging tool 122 for reasons explainedbelow. Note that in the initial configuration shown in FIG. 9 the uppercam wheel 34 assumes a position wherein cams 48 and 50 position theswaging tool 122 and the stripper tube 126 away from the substrate 26.Similarly, lower cam wheel 84 assumes a position wherein cams 98 and 100position the needle 142 and the outer sleeve 146 beneath the supportsurface 152 of the anvil 150 within the aperture 154. The filamentarymember feed assembly 52 is quiescent at this time in the apparatusoperation.

In FIG. 10, the control unit 158 has rotated the lower cam wheel 84which advances both the needle 142 and the outer sleeve 146 upwardlythrough aperture 154 from beneath support surface 152 and intoengagement with the substrate 26. The upper cam wheel 34 is alsorotated, moving the stripper tube 126 downwardly independently of theswaging tool 122, the end of the stripper tube engaging the substrate26. The stripper tube 126, being spring biased as described above, isself-adjusting and engages the substrate 26 regardless of its thickness.

As shown in FIG. 11, the stripper tube 126 is advanced downwardly byfurther rotation of the upper cam wheel 34 causing the needle 142 andthe outer sleeve 146 to penetrate the substrate 26 and form an opening164 therein. Both the needle 142 and the outer sleeve 146 are preferablyheated to a temperature appropriate to melt a portion 166 of the plasticlayer 160 surrounding opening 164 for reasons described below. Note thatthe needle 142 and the outer sleeve 146 are received within the bore 128of stripper tube 126.

As shown in FIG. 12, appropriate further rotation of the upper and lowercam wheels 34 and 84 causes needle 142 to retract beneath the anvilsupport surface 152 and advance the swaging tool 122 into proximity withthe outer sleeve 146. The passageway 130 of the swaging tool 122 alignswith the bore 148 of the outer sleeve 146 and the control unit 158commands motor 54 to spin nip rollers 56 and 58, drawing filamentarymember 70 from its spool (not shown) and advance it downwardly, throughchannel 68 in guide block 66, through passageway 130 in the swaging tool122 (see also FIGS. 1, 5, 5A and 6A) and into outer sleeve 146 until itextends into or through opening 164 in the substrate 26. Note that it isconvenient, but not necessary, to have the outer sleeve 146, which actsas a guide to ensure that the filamentary member 70 is positionedreliably within the opening 164. The aforementioned cam wheel rotationalso advances the stripper tube 126 which forces the substrate 26 intocontact with the support surface 152 on anvil 150.

As shown in FIG. 13, further rotation of the cam wheels 34 and 84 underthe direction of the control unit 158 causes the outer sleeve 146 toretract beneath the anvil support surface 142, thus leaving thefilamentary member 70 within the opening 164 in substrate 26. Theswaging tool 122 is advanced in the wake of the retreating outer sleeveto engage the swaging surface 132 with the substrate 26, preferablyagainst the plastic layer 160. The swaging tool 122 compresses thesubstrate 26 against the anvil support surface 152 with substantiallyconstant force and regardless of the substrate thickness due to thebiasing action of the air spring on which the swaging tool is mounted aspreviously described. The swaging surface 132 deforms the portion 166 ofthe plastic layer 160 surrounding the opening 164 into contact with thefilamentary member 70, thus attaching it to the substrate as well asattaching layers 160 and 162 together. By virtue of the concave conicalshape of the swaging surface 132, the plastic layer portion 166 isformed into a complementary conical shape which provides for a secureattachment of the filamentary member 70 to the substrate 26 with arelatively high pull-out strength. It is preferred to heat the needle142 and the outer sleeve 146, especially when the filamentary member 70is an optical fiber. The heated needle melts the plastic portion 166which then partially melts and fuses with the cladding layer typicallyfound on optical fibers as the portion 166 is swaged. This fusing of theplastic with the cladding layer yields a high strength attachment offiber to substrate. Melting of the plastic layer is also advantageouswith other types of filamentary members 70 as the melted plastic portion166 will fuse to both the filamentary member and the layer 162 whenswaged to create a strong bond. It is also possible to cold work theplastic, i.e., swage the plastic portion 166 into contact with thefilamentary member 70 without first heating it, to obtain an acceptablebond, the attachment depending upon friction and interference betweenthe plastic and the filamentary member, or the plastic being melted bycompressing it between the swaging tool 122 and the anvil supportsurface 152.

FIG. 14 shows the next step in the process whereby rotation of the uppercam wheel 34 first moves the swaging tool 122 out of engagement with thesubstrate 26. The stripper tube 126 is maintained in its position,holding the substrate 26 against the anvil support surface 152 to ensurethat the swaging tool separates cleanly from the substrate, theresometimes being a tendency for the substrate to adhere to the swagingsurface 132. Next the stripper tube 126 is moved upwardly out ofengagement with substrate 26 as indicated by arrow 168. Further lengthof filamentary member 70 may be fed as desired by the feed assembly 52,and the control unit 158 commands a cutting blade assembly 170 intoaction to sever the filamentary member 70. Cutting blade assembly 170 ispreferably mounted on the upper mounting plate 30 between the strippertube 126 and the x-y table 16 as shown in FIG. 3. The apparatus is thenready to repeat the process by repositioning the substrate to a newlocation for the next attachment.

The apparatus according to the invention permits filamentary memberssuch as optical fibers to be attached to substrates precisely, rapidly,repeatedly and reliably, the fibers being held securely in the substrateagainst significant pull-out forces. Although a specific embodiment isshown and described above, variations on the details of the constrictionand operation of the apparatus are contemplated which do not depart fromthe scope of the invention. The x- and y-direction actuators which movethe x-y table are preferably electromechanical but could also bepneumatic or hydraulically driven. Although cams are preferred tocoordinate and control the relative movements of the stripper tube,swaging tool, needle and outer sleeve comprising the insertion assembly,these components could also be moved by means of stepper motors,hydraulic or pneumatic actuators or solenoids controlled by the controlunit. Similarly, the nip rollers forming the feeding assembly also couldbe directly driven by separate motors under the command of the controlssystem. While the swaging surface is preferably conical, it is notlimited to that shape, and could, for example, be hemi-spherical oranother practical shape which promotes swaging of the plastic layer.Furthermore, the motion of the various components is relative and, thus,which components move and which components are stationary is largely amatter of detailed practical design.

1. An apparatus for attaching a filamentary member to a substrate havinga plastic layer, said apparatus comprising: a support surface forsupporting said substrate and being engageable therewith; a needlemovable relatively to said support surface and adapted to penetrate saidsubstrate to form an opening through said substrate; and a swaging toolhaving a swaging surface facing said support surface, said swaging tooland said support surface being movable relatively to one another so asto compress said substrate between said swaging surface and said supportsurface, said swaging tool having a passageway therein for receivingsaid filamentary member, said passageway being alignable with saidopening in said substrate, said filamentary member being positionablethrough said passageway and into said opening, said swaging surfacedeforming a portion of said plastic layer around said opening so as toswage said filamentary member to said substrate.
 2. An apparatusaccording to claim 1, further including a biasing spring on which saidswaging tool is mounted, said biasing spring for biasing said swagingtool against said substrate.
 3. An apparatus according to claim 2,wherein said biasing spring is a pneumatic spring comprising a pistonmovable within a cylinder.
 4. An apparatus according to claim 1, furtherincluding a heater mounted on said needle, said needle being heated andmelting said portion of said plastic layer upon forming said opening insaid substrate.
 5. An apparatus according to claim 1, wherein saidsupport surface defines an aperture therethrough, said needle beingpositioned in alignment with said aperture and movable therethrough toextend outwardly from said support surface and penetrate said substratelayer.
 6. An apparatus according to claim 5, further comprising an outersleeve positioned in alignment with said aperture and having alengthwise oriented bore for receiving said needle therein, said outersleeve being movable relatively to said needle to extend outwardly fromsaid support surface and penetrate said substrate layer, said bore ofsaid outer sleeve forming a guide for directing said filamentary memberinto said opening in said substrate when said needle and said outersleeve have penetrated said substrate and said needle is moved away fromsaid substrate relatively to said outer sleeve.
 7. An apparatusaccording to claim 1, further comprising a stripper tube having alengthwise bore therethrough, said swaging tool being positioned withinsaid stripper tube bore and movable relatively thereto, said strippertube being movable relatively to said support surface and having an endengageable with said substrate for separating said substrate from saidswaging tool when said swaging tool is moved away from said substraterelatively to said stripper tube.
 8. An apparatus according to claim 7,further including a biasing spring on which said stripper tube ismounted, said biasing spring for biasing said stripper tube against saidsubstrate.
 9. An apparatus according to claim 8, wherein said biasingspring is a coil spring.
 10. An apparatus according to claim 1, whereinsaid swaging surface has a concave conical shape.
 11. An apparatusaccording to claim 1, wherein said swaging surface is positioned so asto be directly engageable with said plastic layer.
 12. An apparatus forattaching a filamentary member to a substrate having a plastic layer,said apparatus comprising: a fixed support surface having an aperturetherethrough, said substrate being positionable in facing relation withsaid support surface adjacent to said aperture; a needle movablelengthwise through said aperture toward and away from said substrate,said needle having an end adapted to penetrate said substrate and forman opening therein; a stripper tube having an end positioned facing saidsupport surface and engageable with said substrate, said stripper tubebeing movable lengthwise toward and away from said support surface andhaving a lengthwise bore aligned to receive said needle therein; aswaging tool positioned within said stripper tube bore and movablelengthwise relatively to said stripper tube, said swaging tool having alengthwise oriented passageway therethrough for receiving saidfilamentary member, said swaging tool having a swaging surface at oneend engageable with said substrate; and said substrate being penetratedby said needle when said needle is extended from said support surfaceand said stripper tube end is moved into engagement with said substratethereby forcing said needle through said substrate and creating saidopening, said filamentary member being insertable through saidpassageway and into said opening upon movement of said needle out ofsaid opening, said filamentary member being attached to said substrateupon movement of said swaging tool into engagement with said substrateand compressing said substrate against said support surface, saidswaging surface swaging a portion of said plastic layer surrounding saidopening into contact with said filamentary member thereby fixing it tosaid substrate.
 13. An apparatus according to claim 12, furtherincluding a heater mounted on said needle, said needle being heated andmelting said portion of said plastic layer upon forming said opening insaid substrate.
 14. An apparatus according to claim 12, furthercomprising: a first cam rotatable about a first axis; a first camfollower engaging said first cam and mounted on said stripper tube, saidfirst cam moving said stripper tube toward and away from said supportsurface; a second cam rotatable about a second axis; a second camfollower engaging said second cam and mounted on said swaging tool, saidsecond cam moving said swaging tool toward and away from said supportsurface; a third cam rotatable about a third axis; a third cam followerengaging said third cam and mounted on said needle, said third cammoving said needle through said aperture to extend from or retractbeneath said support surface; and said cams being shaped and rotated soas to coordinate the relative motion of said stripper tube, said needleand said swaging tool for swaging said filamentary member to saidsubstrate.
 15. An apparatus according to claim 14, further comprising anouter sleeve positioned within said aperture and having a lengthwiseoriented bore for receiving said needle therein, said outer sleeve beingmovable relatively to said needle to extend outwardly from said supportsurface and penetrate said substrate layer, said bore of said outersleeve forming a guide for directing said filamentary member into saidopening in said substrate when said needle and said cuter sleeve havepenetrated said substrate and said needle is moved away from saidsubstrate relatively to said outer sleeve.
 16. An apparatus according toclaim 15, further comprising a fourth cam rotatable about a fourth axis,and a fourth cam follower engaging said fourth cam and mounted on saidouter sleeve, said fourth cam moving said outer sleeve through saidaperture to extend from or retract beneath said support surface incooperation with said needle, said stripper tube and said swaging tool.17. An apparatus according to claim 12, further comprising a pair ofrollers mounted for rotation in opposite directions and havingrespective circumferential surfaces engaging said filamentary member onopposite sides thereof, said rollers being positioned above said swagingtool and, upon rotation, feeding said filamentary member through saidpassageway of said swaging tool and into said opening in said substrate.18. An apparatus according to claim 12, further comprising a frame forsupporting said substrate, said frame being positioned between saidsupport surface and said stripper tube and being movable transverselythereto for positioning a predetermined location on said substratebeneath said swaging tool for attachment of said filamentary member atsaid predetermined location.